Charging Piles

The new energy electric vehicle (EV) market is accelerating, fuelled by global efforts to reduce emissions, and this has demonstrated a massive demand for charging infrastructure, not only to increase the number of charging piles, but also for safe and fast charging, which is key to their use. Charging power levels range from 110V for domestic use for normal charging to 800V or even higher for commercial use for ultra-fast charging, and from AC for domestic use to DC for fast charging, where heat is generated quickly and in large quantities by components such as inductive modules and power modules. Therefore, it is important to meet the market demand for fast charging in a safe and sustainable way, and to improve the reliability and durability of the equipment.

Improving the safety, reliability and durability of today's devices is a challenge that Born Industries is helping design engineers to achieve. Boon Industries' thermal interface and insulation materials provide effective solutions for heat dissipation, sealing, potting and insulation for high power density electric vehicle charging systems.

During long-term continuous operation, the charging pile's heat-generating components mainly include the following: power switching devices, connections to semiconductor devices, rectifier transformers, reactor class B insulated windings, and so on.

Thermally conductive silicone gaskets (e.g. BN-FS300, BN-FS500) can conduct the heat generating components in the inductor module to the aluminium shell of the power supply through the thermally conductive gaskets quickly, so as to reduce the temperature inside the inductor module to make it lower than its limiting temperature rise; or conduct the heat of the capacitors and other small power devices through the radiator to the water-cooled side of the board to achieve high temperature heat dissipation, and make use of the charging pile's highly elastic characteristics of thermally conductive gaskets. Play the role of anti-vibration and shock absorption.

Chip is one of the largest heat generating components, and the gap between the chip and the heat sink leads to an increase in thermal resistance, which affects the conduction of heat from the chip. Thermally conductive silicone grease (BN-GK1090) is used to fill the gap between the heat generating device (CPU, GPU, IGBT, etc.) and the heat sink, and can fill the tiny gaps as low as 10μm or less, good thermal conductivity and insulation, high temperature resistance and good reliability, the best choice for the chip heat conduction of the various components of the charging pile.

One-component thermally conductive gel can also be used at the chip of charging pile (e.g. BN-TG350), with low thermal resistance, low oil rate, high reliability, low working pressure, wide temperature range, strong adhesion, reusable, and automatic dispensing process.

Two-component thermally conductive gel is a high thermal conductivity two-component flexible silicone, the product in use 1:1 mixing, can be cured at room temperature, can also be heated to accelerate curing, without any gas release, commonly used to fill the gap in the heating components, after curing to eliminate device assembly tolerances. At the same time, due to the vulcanisation moulding after dispensing assembly, it effectively reduces the stress damage to the components, automatic dispensing design improves the working efficiency, and it can realise the automated assembly and high adaptability of the thermal conductive material.

Most of the charging piles are constructed outdoors, which requires extremely high waterproof level. In the reconstruction or assembly of the charging pile, the use of insulating thermally conductive potting compound, its waterproof, dustproof and high and low temperature resistance and other properties can protect the power module and other electronic components potting protection, more importantly, to enhance its safety and service life. Meanwhile, room temperature curing sealants (e.g. BN-RT200H-T) can be used for plug-in bonding or component sealing.

Flame retardant insulating sheets BN-ZD16 (0.25mm) and BN-FP (0.25mm) used for insulation between modules and chassis have excellent flame retardant properties, anti-aging properties, mechanical properties and electrical insulation properties.